Foster Refrigerator LL2/1MS User manual

Foster Low Level
Counters
with
LCD28 Controller
Service Manual
Re-Issued Version July 2010
ISO 14001
ISO 9001

1
Contents
Manual Information & Health & Safety Notes
1
Environmental Management Policy
2
Disposal Requirements
2
Counter Description, Temperature & Capacilities
3
Controller Operation
3
User Functions
3 to 4
Alarms & Warnings
4 to 6
Controller Parameters
6 to 7
Counter Diagrams
7
Troubleshooting & Notes
8 to 10
Service Manual Information
The products and all information in this manual are subject to change without prior notice.
We assume by the information given that the person(s) working on these refrigeration units are fully trained and
skilled in all aspects of their workings. Also that they will use the appropriate safety equipment and take or meet
precautions where required.
The service manual does not cover information on every variation of this unit; neither does it cover the installation
or every possible operating or maintenance instruction for the units.
Health & Safety Warnings and Information
Make sure the power supply is turned off before making any electrical repairs.
To minimise shock and fire hazards, please do not plug or unplug the unit with wet
hands.
During maintenance and cleaning, please unplug the unit where required.
Care must be taken when handling or working on the unit as sharp edges may cause
personal injury, we recommend the wearing of suitable PPE.
Ensure the correct moving and lifting procedures are used when relocating a unit.
Do NOT use abrasive cleaning products, only those that are recommended. Never
scour any parts of the refrigerator. Scouring pads or chemicals may cause damage by
scratching or dulling polished surface finishes.
Failure to keep the condenser clean may cause premature failure of the
motor/compressor which will NOT be covered under warranty policy.
Do NOT touch the cold surfaces in the freezer compartment. Particularly when hands
are damp or wet, skin may adhere to these extremely cold surfaces and cause frostbite.
Please ensure the appropriate use of safety aids or Personnel Protective Equipment
(PPE) are used for you own safety.

2
Environmental Management Policy for Service Manuals and Duets.
Product Support and Installation Contractors
Foster Refrigerator recognises that its activities, products and services can have an adverse impact upon the
environment.
The organisation is committed to implementing systems and controls to manage, reduce and eliminate its adverse
environmental impacts wherever possible, and has formulated an Environmental Policy outlining our core aims. A
copy of the Environmental Policy is available to all contractors and suppliers upon request.
The organisation is committed to working with suppliers and contractors where their activities have the potential to
impact upon the environment. To achieve the aims stated in the Environmental Policy we require that all suppliers
and contractors operate in compliance with the law and are committed to best practice in environmental
management.
Product Support and Installation contractors are required to:
1. Ensure that wherever possible waste is removed from the client‟s site, where arrangements are in place all
waste should be returned to Foster Refrigerator‟s premises. In certain circumstances waste may be disposed
of on the client‟s site; if permission is given, if the client has arrangements in place for the type of waste.
2. If arranging for the disposal of your waste, handle, store and dispose of it in such a way as to prevent its
escape into the environment, harm to human health, and to ensure the compliance with the environmental law.
Guidance is available from the Environment Agency on how to comply with the waste management „duty of
care‟.
3. The following waste must be stored of separately from other wastes, as they are hazardous to the environment:
refrigerants, polyurethane foam, and oils.
4. When arranging for disposal of waste, ensure a waste transfer note or consignment note is completed as
appropriate. Ensure that all waste is correctly described on the waste note and include the appropriate six-digit
code from the European Waste Catalogue. Your waste contractor or Foster can provide further information if
necessary.
5. Ensure that all waste is removed by a registered waste carrier, a carrier in possession of a waste management
licence, or a carrier holding an appropriate exemption. Ensure the person receiving the waste at its ultimate
destination is in receipt of a waste management licence or valid exemption.
6. Handle and store refrigerants in such a way as to prevent their emission to atmosphere, and ensure they are
disposed of safely and in accordance with environmental law.
7. Make arrangements to ensure all staff who handle refrigerants do so at a level of competence consistent with
the City Guilds 2078 Handling Refrigerants qualification or equivalent qualification.
8. Ensure all liquid substances are securely stored to prevent leaks and spill, and are not disposed of to storm
drains, foul drain, or surface water to soil.
Disposal Requirements
If not disposed of properly all refrigerators have components that can be harmful to the environment. All old
refrigerators must be disposed of by appropriately registered and licensed waste contractors, and in accordance
with national laws and regulations.

3
Low Level Counter Description
The range consists of a choice of 6 models with a choice of two or four drawers.
The cabinets are manufactured as a one piece foam shell with easy clean stainless steel exterior
The cabinets conform to current legislation and exceed the Montreal protocol using zero ODP refrigerants and
insulation.
Temperature is controlled by a LAE microprocessor control with digital temperature display.
Easy accessible condensing unit fitted at the left hand side for ease of servicing.
The standard refrigeration system is integral with an air-cooled condensing unit with the refrigerant distribution into
the evaporator controlled by capillary.
The cooled air is circulated through the evaporator, via the fan/s into the storage area.
Coated coils prevent corrosion and prolong refrigeration life.
Magnetic gaskets giving a positive door seal.
Temperature and Capacities
Model
LL2/1MS
LL2/1MD
LL1/2H
LL2/1MDRW
LL2/2M
LL2/4M
Storage
Temperature
-2 to +2°C
-2 to +2°C
+1 to +4°C
-2 to +2°C
-2 to +2°C
-2 to +2°C
Dimensions
(w x d x h) mm
1244x800x646
1244x800x646
1600x700x700
1030x 797x646
1900x800x646
1900x800x646
Internal
Dimensions
(w x d x h) mm
566x670x368
566x670x139
357x570x487
566x670x139
566x670x368
566x670x139
Nett Capacity
(litres)
140
140
222
140
279
279
Number of
Drawers
1
2
2
2
4
2
Maximum Weight
Load per drawer
40kg
40kg
40kg
40kg
40kg
40kg
Pan Size
GN 2/1
(max 200mm
deep)
GN 2/1
(max 100mm
deep)
GN 2/1
(max 200mm
deep)
GN 2/1
(max 100mm
deep)
GN 2/1
(max 200mm
deep)
GN 2/1
(max 100mm
deep)
Number of
Castors Supplied
3 x Swivel
Braked (front)
3 x Swivel
(rear)
3 x Swivel
Braked (front)
3 x Swivel
(rear)
3 x Swivel
Braked (front)
3 x Swivel
(rear)
2 x Swivel
Braked (front)
2 x Swivel
(rear)
4 x Swivel
Braked (front)
4 x Swivel
(rear)
4 x Swivel
Braked (front)
4 x Swivel
(rear)
NOTE
Maximum weight of griddle not to exceed 120kg ensuring the weight is evenly distributed across the
worktop.
If the legs are positioned over the unit compartment please ensure the load is evenly distributed by
mounting the griddle into heavy duty metal channels
Controller Operation
LCD 28CS4E-B (00-555739) Controller Operation Guidelines
LCD 16 Display (00-555740)
Initial Start Up.
Start Up & self Test:
The indication is only displayed during the first three seconds following the mains electrical power being applied to
the unit. During this period the controller performs a self-check.
Once the self-check has been completed will be displayed.
Press and hold for three seconds. The unit will start and the air temperature will be displayed.
OFF

4
Check temperature set point.
Important to note that the ability to increase and decrease the set point is not a function available to the user as the
set point is fixed. To make adjustments to the set point it is necessary to access the parameter and alter SPL and
SPH accordingly.
Check set point by pressing the button
To increase set point press + until required temperature is displayed.
To decrease set point press + until required temperature is displayed.
Factory Temperature Set Point
Refrigerator +1°C to +4°C
Meat 0°C to 2°C.
Freezer -18°C to -21°C.
Exit from set up occurs after 10 seconds if no button is pressed.
Manual Defrost.
To initiate a manual defrost press and hold will be displayed release.
On completion of the defrost will be displayed until the cabinet temperature is achieved and then it will
revert to displaying the normal cabinet temperature.
Set Unit to Standby.
Press display shows
Standby Indication
This indication is displayed while the unit is not operating but with mains power applied to the unit. This mode may
be used for internal cleaning regimes and short periods when the unit is not required.
For extended periods of inactivity the mains supply should be isolated.
Alarm and Warnings
High temperature alarm
Will be displayed.
The alarm will sound but can be silenced by pressing any of the buttons, however it will return after the
pre-set designated period. The unit returning to normal operating temperature will automatically cancel the alarm.
Possible Causes: Evaporator fan not working. Restricted airflow through airduct. Evaporator iced up. Compressor
not working.
Low temperature alarm.
Will be displayed.
The alarm will sound but can be silenced by pressing any of the buttons and the unit will continue to operate,
however it will return after the pre-set designated period. The unit returning to normal operating temperature will
automatically cancel the alarm.
Possible Causes: Controller faulty (not switching compressor off). Compressor secondary relay will not de-
energise (low temperature models).
Door Open Alarm. (Only applies to cabinets fitted with door switches.)
Will be displayed.
The alarm will sound but can be silenced by pressing.
The display will continue to display the alarm message until cancelled by shutting the door.
If the alarm cannot be cancelled by doing this call your Foster Authorised Service Company.
Possible Causes: Faulty door switch. Door left open for more than 5minutes.
High Pressure Alarm (Only applies to machines fitted with a condenser probe).
Will be displayed
This alarm relate to the condenser which must be checked and cleaned at regular intervals the frequency being
determined by site conditions.
The alarm will sound but can be silenced by pressing any of the buttons and the unit will continue to operate,
however it will return after the pre-set designated period. The unit returning to normal operating temperature will
automatically cancel the alarm.
Possible Causes: Condenser fan not working. Condenser blocked/ dirty. Condenser obstructed.
dEF
HI
LO
REC
OFF
DO
HP

5
Air Temperature Probe Failure.
Will be displayed.
The alarm will sound but can be silenced by pressing any button.
There is no further action that can be taken by the user in this instance. During this period the unit will continue to
operate but have a reduced performance.
Action: Replace Probe.
Evaporator Temperature Probe Failure. (Automatic Defrost Cabinets Only)
Will be displayed.
The alarm will sound but can be silenced by pressing any button.
There is no further action that can be taken by the user in this instance. During this period the unit will continue to
operate satisfactorily, but this failure will have an effect on the defrost and therefore efficiency if allowed to
continue.
Action: Replace Probe.
Information Menu
Pressing and releasing activates the information menu. From this menu you can display the
temperature relating to T1 (air probe), T2 (evaporator probe, if fitted) and T3 (condenser probe, if fitted).
The maximum temperature (THI) and the minimum temperature (TLO) the cabinet has achieved since it was last
re-set.
The total operating time of the condenser (CND), since it was last cleaned, and the keyboard status (LOC).
The information to be displayed can be selected sequentially by pressing repeatedly or scrolling
through the menu using the or buttons.
Once selected press to display the value
Exit from the info menu by pressing or is automatic after 6 seconds if no buttons are pressed.
To reset the temperature settings recorded in THI and TLO and the hours counted in CND, access the info
menu press to display the value plus simultaneously for resetting to be completed.
To check the LOC status scroll through to LOC, press to display status –YES to lock keys. –NO to
leave keys accessible.
NOTE: with the keys locked it is not possible to turn the unit OFF or ON or to check the set point
Parameter Setting and Adjustment
It is strongly advised that before adjusting any Service Parameters a thorough understanding of the
following instructions should be obtained.
The parameters are accessed by pressing the following keys in succession + “set” + and
keeping them pressed for 5 seconds.
After this period the first parameter „SCL‟ will be displayed.
Press button to pass from one parameter to the next and button to go back.
Press to display the value + or to change it.
Exit from set up is by pressing or is automatic if no buttons are pressed for 30 seconds
NOTE:
When receiving a replacement controller the unit will be set with the default settings. Change the settings to those
relating to the particular model. After changing parameter „SCL‟ from „1‟ to „2‟ moving through parameters „SPL‟,
„SP‟, „FDD‟, IISL‟ and „IISP‟ you may find that „-or‟ will be displayed. „-or‟ indicates that the control setting is out of
range.
To get the parameter back into range, for example „SPL‟, press to display the value +
E2
E1

6
continue pressing both buttons until the display shows the temperature required then release both buttons.
Use the same procedure to adjust all of the parameters displaying „-or‟.
Fuzzy Logic is not incorporated in this model as no door switches are fitted.
Controller parameters for models manufactured prior to March 1st 2006
The parameter settings for the cabinets produced prior to March 1st 2006 can be altered to the following parameter
lists and will function as described above.
Note
Parameter FPC is not included.
LCD 28CS4E-B (00-555735) Controller Parameter lists
Note: as of 16-05-2008 temperature set point „SP‟ set to +1°C for unit to operate between +1°C and +3°C.
Note: On early versions of the controller parameter „FPc‟ is not included in the set up, this will have no
bearing on the operational function of the controller.
Mnem.
Definition
Min.
Max
Default
Dim.
VALUES (A)
ScL
Readout scale
1°C; 2°C; °F
1°C
flag
2
SPL
Minimum set point [ I ]
-30
SPH
-25
°C
1
SPh
Maximum set point [ I ]
SPL
30
10
°C
4
SP
Set point [ I ]
SPL
SPH
-20
°C
1
hYS
Thermostat hysteresis [ I ]
0.1
10
2.5
°K
3
crt
Minimum compressor rest time
0
30
1
min.
1
cdc
10 min. run cycle with PF1
0
10
6
min.
6
cSd
Compressor Stop delay after door open
0
30
1
min.
1
dFr
Defrost frequency [ I ]
0
24
3
1/24h
4
dLi
Defrost end temperature
-30
30
15
°C
20
dto
Maximum defrost duration
1
120
20
min.
20
dty
Defrost type
FAN; ELE; GAS
ELE
flag
OFF
drn
Drain down time
0
30
3
min.
2
ddY
Display control during defrost
0
60
10
min.
10
Fid
Fan operation in defrost
NO
YES
NO
flag
YES
Fdd
Evaporator. Fan re-start
-30
30
-50
°C
10
Ftc
Fan timed control [ I ]
NO
YES
YES
flag
NO
FPc
Evaporator fan On / Off Ratio
0
3
1
flag
0
Atl
Low temperature alarm
-12
0
0
°K
-5
Ath
High temperature alarm
0
12
5
°K
5
Atd
Temperature alarm delay
0
120
30
min.
90
Ado
Door alarm delay
0
30
5
min.
5
Aht
Condenser HP Alarm
0
70
60
°C
60
Ahm
AHT alarm management
NON; ALR; STP
NON
flag
NON
Acc
Condenser cleaning
0
52
0
wks
0
hdS
Eco->Heavy Duty sensitivity
1
5
3
flag
3
11SM
2nd parameter set management
NON; MAN; HDD
NON
flag
NON
11SL
Minimum set point [ II ]
-30
IISH
-25
°C
-25
11SH
Maximum set point [ II ]
IISL
30
10
°C
10
11SP
Set point [ II ]
IISL
IISH
-20
°C
-20
11HY
Thermostat hysteresis [ II ]
0.1
10
3
°K
3
11dF
Defrost frequency [ II ]
0
24
1
1/24h
1
11Ft
Fan timed control [ II ]
NO
YES
NO
flag
NO
Sb
Stand By button function
NO
YES
YES
flag
YES
dS
Door switch enabling
NO
YES
NO
flag
NO
oAu
AUX Output Control
NON; 0-1; ALR
ALR
flag
NON
oS1
Air probe offset
-12.5
12.5
0
°K
0

7
t2
Evaporator. Probe enabling
NO
YES
YES
flag
NO
OS2
Evaporator. Probe offset
-12.5
12.5
0
°K
0
T3
Condenser. Probe enabling
NO
YES
NO
flag
NO
oS3
Condenser. Probe offset
-12.5
12.5
0
°K
0
tLd
Logging Temp. Delay
1
30
5
min.
5
Sim
Display slowdown
0
100
3
exp.
3
Adr
Unit address
1
255
1
exp.
1
Unit Diagrams
Standard Low Level Counter Condensing Unit Assembly
Standard Low Level Counter Evaporator Assembly
LL2/1 MD RW (Spirit Spec) Detail
LL2/1 MD RW (Spirit Spec)
Evaporator Detail

8
Troubleshooting
Problem
Possible Cause
Solution
Compressor will not start
No voltage in socket
Use voltmeter to check
Electrical conductor or wires may be
cut
Use ohmmeter to check for
continuity
Defective electrical component:
thermostat, relay, thermal protector
etc
Replace defective component
Compressor motor has a winding
open or shorted
Measure ohmic resistance of main
and auxiliary winding using
ohmmeter. Compare with correct
values
Compressor stuck
Change compressor
Temperature control contacts are
open
Repair or replace the contacts
Incorrect wiring
Check wiring diagram and correct
Fuse blown or circuit breaker
tripped.
Replace fuse or reset circuit breaker
Power cord unplugged
Plug in power cord.
Controller set too high
Set controller to lower temperature.
Cabinet in defrost cycle
Wait for defrost cycle to finish
The temperature is too cold
Controller is set at a very cold
position
Set to warmer position and check if
the compressor stops according to
controllers operating range.
Controller does not disconnect the
condensing unit
Check the insulation of the
thermostat. If problem persists,
change the thermostat
Control contacts are stuck closed
Change the control. Check
amperage load
Defective or incorrect temperature
control
Determine correct control and
replace.
The temperature is not cold
enough
Controller is set at a very warm
position
Adjust to colder setting
Condenser is dirty
Clean condenser
The refrigerator has been placed at
an inadequate location
The unit must not be near stoves,
walls that are exposed to the sun, or
places that lack sufficient air flow.
Compressor is inefficient or there is
a high pressure due to the air in the
system
If there is air in the system, purge
and recharge
Iced up evaporator coil
Check temperature control,
refrigerant charge, and defrost
mechanism. Remove all ice
manually and start over.
Restriction in system
Locate exact point of restriction and
correct
The refrigerator has been used
improperly
The shelves must never be covered
with any type of plastic or other
material that will block the circulation
of cold air within the refrigerator.
Too many door openings
Advise user to decrease if possible
Excessive heat load placed in
cabinet
Advise user not to put in products
that are too hot.

9
The refrigerator has been
overcharged with the refrigerant gas
Check to see if condensation or ice
crystals have formed on the suction
line. If so, charge with the correct
amount of gas.
The refrigerant gas is leaking
Find the location of gas leak in order
to seal and replace the defective
component. Change the drier.
Perform a good vacuum and
recharge unit.
The evaporator and/or condenser
fans are not working
Check electrical connections and
make sure that the fan blade isn‟t
stuck. Replace the fan motor if it
doesn‟t work.
Blocking air flow
Re-arrange product to allow for
proper air flow. Make sure there is at
least four inches of clearance from
evaporator.
Fuse blown or circuit breaker tripped
Replace fuse or reset circuit
breaker.
Electrical Shocks
Wires or electrical components are
in direct contact with metallic parts.
Check for appropriate insulation on
the connections of each component.
Noise
The refrigerator is not properly
levelled
Check if the noise goes away after
you level the refrigerator
The condenser is not fastened
correctly. Copper tubing is in contact
with metal
While the compressor is working,
check to see if metal parts are in
contact with one another and/or if
the screws that fasten the
condenser are tightened.
The evaporator and/or condenser
fans are loose
Check if the fans are securely
fastened. Also, check if the fan
blades are loose, broken or crooked.
If so, change the faulty blade.
Compressor has an internal noise
If the noise persists after all other
measures have been taken, it may
be originating from the compressor.
Loose part(s)
Locate and tighten loose part(s)
Extreme condensation inside the
refrigerator
Controller is set at a very cold
position
Set the controller to a warmer
position & check to see if
compressor stops as should.
The outside environment‟s relative
humidity is very high (over 75%)
This type of occurrence is caused by
local climatic conditions and not by
the refrigeration unit.
The refrigerator door wont shut
completely
Check the door and/or the magnetic
gasket. Adjust the door hinges if
needed; replace the gasket if
broken.
The refrigerator had been placed at
an inadequate location
The unit must not be near sources
that produce too much heat.
No illumination (Glass door
models only)
The light switch is “off” position
Press the light switch to “on” position
False contact on the light switch, the
fluorescent tube, or the ballast
Inspect all connections
Light switch, ballast and/or
fluorescent tube are damaged
Replace the damaged component.
Condensing unit runs for
long periods of time
Excessive amount of warm product
placed in cabinet
Advise user to leave adequate time
for products to cool down

10
Prolonged door opening or door ajar
Advise user to ensure doors are
closed when not in use and to avoid
opening doors for long periods of
time.
Door gasket(s) not sealing properly
Ensure gaskets are snapped in
completely. Remove gasket and
wash with soap and water. Check
condition of gasket & replace if
necessary
Dirty condenser coil
Clean condenser coil
Evaporator coil iced over
Unplug unit and allow coil to defrost.
Make sure thermostat is not set too
cold. Ensure that door gasket(s) are
sealing properly. Select manual
defrost and ensure system works.
Notes

11
Foster European Operations
France
Foster Refrigerator France SA
Tel: [phone]. Fax: [phone].
Email: [e-mail]
Germany
Foster Refrigerator Gmbh,
Tel: [phone]. Fax [phone].
Email: [e-mail]
Foster Refrigerator
Oldmedow Road
Kings Lynn
Norfolk
PE30 4JU
Tel: [phone]
Fax: [phone]
Website: www.fosterrefrigerator.co.uk
Email: [e-mail]
a Division of „ITW (UK) Ltd‟
LOWLEV CAB LCD28/SM 07/10